Cement plant Mechanical Maintenance

BY Mohamed Shaaban Abdou Aly Mechanical Engineer +201000598568 or +201003839638 Mohamed_shaban63@yahoo.com

  • quarry and Crushers area:-
  • Reclaiming and stacking station:-
  • Raw mills area:-
    • Apron weight feeders (feed & arrange the charging materials to the mills)
    • Grinding raw mill:-
  1. Balls tube mill (horizontal mill) ii. vertical mill (rollers mills)

Raw mill (balls tube mill (horizontal mill).

. Single drive pion and gear box  . Duel drive pinions with two gearboxes & girth gear.  . Symmetry gear box drive and torsion shaft with the outlet mill head.

Mill Dual drive, and girth gear.

  • Auxiliary & Main drive gear boxe
  • Pinions and Girth gear two half and torsion shafts and journal bearing of the pinions shafts.
    • Repair the pitting and broken gears tooth of the girth gear (heating & welding and building up and grinding).
    • Reverse the girth gear and pinion
  • Mill drive Lubrication circuit of the girth gear (CIBLATIEN) and lubrication of the journal bearing and gear bo

 

  • Mill body:-
    • Inlet & outlet bearing (inlet & outlet journal bearing or outlet sho bearing).
    • Mill shell, and lining plates of the mill shell and inlet & outlet mill head liners and intermediate and outlet diaphragms lining plates (blind and slotted) at the first

and second chambers, and lifters at the first chamber of the mill.

  • Repair by welding the cracks of the mill shell.
  • Inlet & outlet trunnion of the mill and journal bearing alloys and lubrication circuit high & low pressure pumps (high pressure pump to lift the mill trunnion at start

the mill & low pressure pump to lubricate the trunnion during the operation )

  • Hydraulic and lubrication syste
  • Main filter (control and condition gas either to be used in raw mills or cool it down to comply with environment regulations) and conditioning tower (cooling).
  • P & ID fan (to suction the hot gases from cooler in which used for combustion in kiln and gases to preheat kiln feed material)
  • Air sliding (to transport the raw material to the chain bucket elevators to charge the raw silos)
  • Kiln area:-
    • Kiln

Types of the kiln feed (Air lift – chain bucket elevators – chamber pump – IBAU pump – peter pump, etc.) to lift and charge the pre-heater tower by the raw materials

  • Pre-heater tower (consisting of the cyclones to preheating the raw materials to 900 C0 )
  • Rotary kiln

Kiln Dual drive, and girth gear.

  • Auxiliary & Main drive
  • Girth gear two half with the G.G rim (spring plats).
  • The G.G is a spur gear tooth, and it is two half’s and assembled with the kiln shell by the spring plates, and the drive pinions of the G.G assembled on the pinion

shafts with shrink disk, or it fit directly on the shafts and the shafts are assembled on the journal bearing alloys.

  • Repair the pitting and broken gears tooth of the girth gear (heating & welding and building up and grinding).
  • Reverse the girth gear and pinions.
  • Kiln drive Lubrication of the girth gear (CIBLATIEN) and lubrication of the journal bearing and gear bo

–  Kiln dual drive consist of (two gear boxes and 2 torsion shafts and one girth gear (two half) and two pinions with the journal bearing of pion shafts and electrical motors.

Kiln supports

  • Kiln tyre and rollers support with journal bearing.
  • Kiln thrust table and the hydraulic circuit (to lift the kiln)
  • Kiln seals and lamella (inlet and outlet)

Inlet and outlet Kiln seals and lamella (inlet and outlet)

  • Clinker Cooler

(Cross bar – grate cooler) hydraulic or mechanical drive.

  • Clinker cooler hammer crusher and flywheel
  • Kiln Bypass
  • Clinker transportation and clinker silos:-
    • pan conveyor (transport and charge the clinker to the clinker silos)
    • Buckets & rails & wheels (rollers) & guide rollers & drive and driven sprocket & drive gearbox & check & adjusted the rails alignment, e
    • Clinker silos
    • pan conveyors or the drag chain (transport and charge the clinker from clinker silos to cement mills)
  • Cement mill area:-
    • Pan conveyors or drags chain.
    • Belt conveyors and weight feeders (for the clinkers and gypsum)
    • Cement mill (balls tube mill (horizontal mill)).

. Single drive pion and gear box  . Duel drive pinions with two gearboxes & girth gear. Symmetry gear box drive and torsion shaft with the outlet mill head.

 

Mill Dual drive, and girth gear:-

  • Auxiliary & Main drive gearbo
  • Pinions and the Girth gear two half and torsion shafts and journal bearing of the pinions shafts.
    • Repair the pitting and broken gears tooth of the girth gear (heating & welding and building up and grinding).
    • Reverse the girth gear and pinions.
  • Mill drive Lubrication circuit of the girth gear (CIBLATIEN) and lubrication of the journal bearing and gearbo

Mill body:-

  • Inlet & outlet bearing (journal bearing).
  • Mill shell, and lining plates of the mill shell and inlet & outlet mill head liners and intermediate and outlet discharge diaphragms lining plates (blind & slotted) at the

first & second chambers.

  • Repair by welding the cracks of the mill shell.
  • Inlet & outlet trunnion of the mill and journal bearing alloys and lubrication circuit high & low pressure pumps (high pressure pump to lift the mill trunnion at start

the mill & low pressure pump to lubricate the trunnion during the operation )

  • Water Spray cooling system at the outlet of the mill, (water pump and compressed air).
  • Hydraulic and lubrication syste
  • Vibrator or dynamic separator of the cem
  • Mill fan and cement bag filters or EP filt
  • Cement pneumatic transportation (IBAU OR FULLERS or chamber pump) pumpers
  • Compressor to charge the Cement pumps with compressed air and conveying the cement material to cement silos
  • Cement silos and packing machines area:-
    • Cement silos and aeration system and filtration un
    • Air slide to charge the cement material from the silo to center pin.
    • Center pin
    • air slide to charge the cement from center pin to the feed screw conveyor
    • feed Screw conveyors
    • Vibrator screen
    • Rotary feeder
    • Packing machine (HAVER and BOKER), 8 spouts / machine and pneumatic circuit (pneumatic valves and cylinders).

Packing machine (HAVER & BOCKER) 8 spouts with it’s drive unit and the pneumatic circuit (sliding gat air cylinder with control valves on the rotary feeder, sliding

gate air cylinder with control valves of the turbine spout, bag holder air cylinder with control valves, bag seat air cylinder with control valves…..etc.) (Check and

maintain the pneumatic directional valves and cylinders…… etc. and check the bearing of the turbine spouts and sealing etc., and check the drive unit of the

machine (drive and driven pulleys and machine bearing with the hollow shaft))

  • Return screw conveyor
  • Bucket elevator.
    • Drive unit (gearbox with backstop, and hydraulic coupling and flexible coupling at the high & low speed
    • Buckets of the bucket elevator, assembled with the chain or the rubber belt by fixation bo
    • Chain or belt to assemble the buckets in the chain if the type chain bucket elevator or the rubber belt if the type belt bucket elevato
    • Drive sprocket of the bucket elevator (segment teeth or one piece teeth sprocket) or drive drum if it belt bucket elevato
    • Driven sprocket of the bucket elevator or driven drum of the type rubber belt bucket elevator
    • Tension unit at the driven sprocket (or driven drum if it belt bucket elevator)
    • Feeding and discharging chu
  • Compressors and dryers
  • Bags belt conveyo
  • Truck loading or the baulk loading devices (telescopic spout).

Maintenance of the Gearboxes:-

 

Usually use the gearboxes to reduction in the speed and increasing the torque according to the gearbox designation and the internal reduction stages.

  • Gearbox consisting of:-
    • High speed and low speed shafts with bearing and sealing
    • Pinion (bevel helical or spur tooth) in the first s
    • Gears stages with the shafts and bearing
    • Gearbox housing (lower and upper housing)
    • Gears types with the solid or hollow output shafts:-
      • Spur gears (single and double).
      • Helical gears.
      • Bevel gears.
      • Bevel helical gears (spiral gears).
      • Spur rack g
      • Worm ge etc.
    • maintain the gear boxes:-
      • Check the vibration by vibration pin and check the bearing temperature by hand pyrometer and check the No
      • Open the upper cover and check the bearing clearanc
      • Check and measuring the backlash of the gears meshing.
      • Take a footprint for the contact area between the meshing teeth, and check the surface of the gears teeth.
      • Check axial clearance of the gears shafts bearing (fixed and free bearing).
      • Check and inspect the teeth cracks by T (Penetrant test).
      • Check the lubrication cycles of the gear stages and bearing, and check the situation of the oil.
      • Check the alignment of the low and high speed coupling.
      • Check the fixation of the gears boxes and check the soft foo
      • Repair the pitting and broken gears tooth (heating & welding and building up and grinding).
      • Fabricate & change the damaged gears of the stages gearbo

Raw & cement material pumps {Screw conveyor pumps (peter pump & IBAU pump &fuller pump or chamber pump etc.)}:-

It use to conveying the material like the raw materials and cement materials from the mill to silos, using the screw element and compressed air.

  • Electrical moto
  • Flexible coupling.
  • Screw shaft
  • Housing of the screw
  • Pump housing and feeding hopp
  • Flap gate with counter arm
  • Mixing room of the material with the compressed air.
  • Drive and driven bearing
  • Compressor to supply the pump by the compressed a

 

Dust collectors:-

The dust collected and filtration {EP filter (electrostatic precipitator filters), or bags filter}.

Bags filter Consists of:-

  • Suction fan & Exhaust du
  • Bags and bags Cages.
  • Filter housing, (suction chamber & hoppers of collecting the materials (dust), inlet & outlet ducts).
  • Pneumatic system & Compressed air and pulsing air jet, to cleaning the bags from the du
  • Screw conveyor or air slid, to return the filtration material to the cy

 

Vertical mill (roller mill):-

Use it to grinding the clinker or raw material by the grinding table and rollers with the hydraulic system, and there is a separator at the outlet of the mill to separate

the rough materials (reject materials), etc.

 

Utilities:-

  • Pumps:-

. Hydraulic pump. . Water pump.  .Raw & cement material pumps {Screw conveyor pumps (peter pump & IBAU pump &fuller pump or chamber pump etc.)}

  • Hydraulic pump.

Use the hydraulic pumps to operate the hydraulic circuit or lubrication cycle and there are many types of the hydraulic pumps:-

  • Piston pump.
  • Gear pump, (internal gear pump or external gear pump).
  • Vane pump.
  • Screw pump
  • Axial pumps, etc.)
  • Water pumps
  • Air system, (compressors & blowers & air dryers) Compressor:-

The compresses producing compressed air through compressor rotor element and the gear box, and the compressor brands (ROLLAIR or AERZENER or Atlas COPCO).

  • AERZENER (AERZEN type VM410-3B or AERZEN type VM410-2B)
  • ROLLAIR (ROLLAIR 100 B5, etc.).
  • Atlas COPCO (Atlas COPCO ZA355, e)

Blower:-

Using the blowers to moving the air with high capacity (unit m3/h)

Air Dryers:-

Using the dryers for the compressed air which sullied to the pneumatic circuit to drying the air before entering to the pneumatic valves and cylinders.

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